Electrical connector for mid-cable termination

Abstract: An initially integral terminal assembly (84) useful for terminating a selected conductor (74) of a flat power cable (72) having at least two insulated conductors (74) includes upper and lower plate sections (26) extending in diverging directions from a common bendable hinge (46) defining a cable receiving region therebetween. Each plate section (26) has at least a first portion (28) corresponding to the first conductor (74) and a second portion (36) associated with a second conductor of the cable (72). Each portion (28, 36) further includes conductor terminating regions (30,54) intermediate opposed upstanding side walls of the upper and lower plate sections (26,50). One of the terminating regions (30,54) of a selected one of the first or second portions (28 ,36) of the plate sections (26,50) corresponding to a selected cable conductor (74) contains respective arrays of shearing means (56) adapted to penetrate the selected conductor (74) inserted therebetween upon the upper and lower plate sections (26,50) being pressed together to shear the insulation and the selected conductor (74) The terminating regions (36, 54) of the portions (28,38) corresponding to the remaining cable conductors (74) are severed from the assembly (84) prior to terminating the assembly to the cable (72). Upon termination the assembly (84) is electrically connected to the selected conductor (74) and electrically isolated from the remaining conductors (74).

Description: The present invention relates to the field of electrical connectors and more particularly to terminals for use with flat power cables. U.S. Patent Nos. 4,867,700 and 4,859,204 disclose terminals which are crimped onto a flat power cable by penetrating the insulation covering the cable's flat conductor and also shearing through the conductor at a plurality of locations. The cable is of the type entering commercial use for transmitting electrical power of for example 75 amperes nominal, and includes a flat conductor one inch wide (1 inch = 25.4 mm) and about 0.020 inches thick with an extruded insulated coating of about 0.004 to 0.008 inches thick over each surface with the cable having a total thickness averaging about 0.034 inches. One embodiment of terminal is stamped and formed of sheet metal and includes a pair of opposing plate sections disposed along respective major surfaces of the cable and including opposing termination regions extending transversely across the cable. Each terminating region includes a transverse array of alternating shearing wave shapes and relief recesses of equal width, the relief recesses defined by arcuate projections extending away from the cable-proximate side, and the wave shapes extending outwardly from the cable-proximate side and toward relief recesses in the opposed plate section. Each shearing wave shape has a transverse crest between parallel side edges, and the side edges of the corresponding relief recesses are associated with the wave side edges to comprise pairs of shearing edges, preferably with zero clearance. When the plate sections are pressed against a cable section disposed therebetween the crests of the wave shapes initiate cable shearing by their axially oriented side edges cutting through the cable insulation and into and through the metal conductor. The wave shapes extrude the sheared cable strips outwardly into the opposing relief recesses as the shears propagate axially along the cable for limited distances, forming a series of interlocking wave joints with the cable while exposing newly sheared edges of the cable conductor for electrical connection therewith. In U.S Patent No. 5,219,303 a pair of upper and lower terminal portions coextending from a hinge and defining a cable receiving region therebetween, are used for terminating to flat cable upon the upper and lower plate sections being pressed toward each other and into flat cable. When used with single-conductor cable the assembly provides two terminations across the width of the cable. When used with dual-conductor cable in contradistinction to single-conductor cable, the connector either commons the two conductors or tooling can sever ligatures that initially join two halves of the upper terminal portion to each other and two halves of the lower terminal portion to each other. In one embodiment a contact section can extend from the hinge-remote end of either the upper or lower terminal portion and is adapted to be mounted to a terminal post for example for midcable termination. When used with dual-conductor cable, the ligatures are severed as previously described and the contact section connects only one particular conductor of the dual-conductor cable, that is the conductor at the hinge remote side of the cable. Thus, in order to electrically connect the other conductor of the dual-conductor cable, the assembly must be rotated 180 degrees such that the contact section extends from the opposite longitudinal edge of the cable, which is now the hinge remote conductor. The location of the contact sections and hinge sections of the connector will therefore alternate along the sides of the cable depending upon which conductor of the dual cable is being terminated, as shown in Figure 4. It is desired to provide a terminal for interconnecting selected conductors in a dual-conductor cable wherein the contact section extends along the same edge of the cable, regardless of which conductor has been terminated. It is also desired to provide an initially integral terminal assembly which can interconnect a selected conductor of a dual conductor flat power cable at any location along a continuous length thereof and have a contact section extending from the termination for mating with a complimentary contact section of another electrical article such as a terminal post of a power supply or other conductor means. It is additionally desired to provide an initially integral terminal assembly which can interconnect selected conductors of each of two-dual-conductor flat power cables. The present invention is a terminal defined by the features of claim 1. It serves for terminating an intermediate portion of a selected conductor of a flat power cable having at least two insulated conductors, each conductor being spaced from an adjacent conductor by an insulating section. The assembly includes a cable proximate terminal body member which includes opposing upper and lower plate sections extending in diverging directions from a common bendable hinge. The upper and lower plate sections are initially angularly spaced to receive a portion of a continuous length of at least one flat cable therebetween and transversely with respect to the upper and lower plate sections. Each of the upper and lower plate sections have at least a first portion corresponding to the first conductor of the cable and a second portion associated with a second conductor of the at least one cable. The first and second portions are separated by a transverse aperture associated with the insulated section between the first and second conductors. Each of the first and second portions further include conductor terminating regions intermediate opposed upstanding side walls of the upper and lower plate sections. One of the terminating regions of a selected one of the first or second portions of the upper and lower plate section corresponding to a selected conductor of the cable may contain respective arrays of shearing means adapted to penetrate the selected conductor of the cable portion inserted therebetween upon the upper and lower plate sections being pressed together to shear the insulation and the selected conductor. In accordance with the present invention, the terminating regions of the others of the first and second portions corresponding to the remaining conductors of the cable are severed from the assembly prior to terminating the assembly to the cable. Upon inserting the cable between the upper and lower plate sections and pressing the plate sections together the shearing means of the selected terminating region shear the insulation of the selected conductor for electrical connection therewith and the remaining conductors remain electrically isolated from the terminated conductor. In one embodiment the selected one of the first and second portions is adjacent the hinge. In another embodiment the selected one of the first and second portions is remote from the hinge. The terminal assembly may further include a contact section that extends from one end of the upper or lower plates and remote from the hinge. It is an advantage of the present invention to provide an initially integral terminal assembly for ease of application to a selected conductor in at least one flat power cable having at least two insulated conductors. It is another advantage of the present invention to provide a terminal assembly for connecting a selected conductor of a bus bar having at least two conductors extending therein to an electrical article, the terminal assembly including a contact section extending from the termination for mating with a complementary contact section of another electrical article. It is a further advantage of the invention to provide a terminal assembly for termination to a selected conductor of a multi-conductor cable while remaining electrically isolated from the other conductors of the multi-conductor cable. A terminal for terminating an intermediate portion of a selected conductor of a flat cable having at least two conductors separated by an insulating section, the terminal comprising upper and lower plate sections connected by a hinge portion and being foldable along the hinge portion to form a cable receiving recess between the upper and lower plate sections, each of the plate sections having first sections remote from the hinge portion and being in alignment with a first one of the conductors, and each of the plate sections having second sections near the hinge portions and in alignment with a second one of the conductors, the terminal has terminating sections on the upper and lower plate sections only in the first sections for electrically terminating to the first conductor or in the second sections for electrically terminating to the second conductor. Embodiments of the present invention will now be described by way of example with reference to the accompanying drawings, in which: Figures 1 through 4 illustrate a prior art terminal assembly for cable. Figure 1 is an isometric view of a stamped and formed blank of the prior art connector prior to bending at the integral hinge joint. Figure 2 is an isometric view of the connector of Figure 1 after bending the assembly. Figure 3 is a side view of the connector Figure 2 with a cable inserted between the two portions. Figure 4 is a dual-conductor cable having two connectors of Figure 2 terminated thereto, one terminal electrically terminated to each of the conductors of the cable. Figure 5 is an isometric view of one embodiment of the terminal assembly of the present invention illustrating a connector blank prior to bending at the integral hinge joint. Figure 6 is an isometric view of the assembly of Figure 5 after bending at the hinge joint. Figure 7 is a side view of the assembly of Figure 6 prior to termination to selected conductor of the dual-conductor cable. Figure 8 is a plan view of the terminal assembly of Figure 5 after termination the conductor. Figure 9 is a plan view of a blank used to form a second embodiment of the present invention. Figure 10 is an isometric view of the formed blank of the terminal assembly of Figure 9. Figure 11 is an isometric view of the terminal assembly of Figure 9 after bending at the hinge joint. Figure 12 is a side view of the terminal assembly of Figure 11 prior to insertion of the cable. Figure 13 is a plan view of the terminal embodiment of Figure 11 terminated to the other conductor of a dual conductor cable. Figure 14 is an isometric view of a representative terminal assembly of one embodiment of the present invention applied to a selected conductor of a flat dual-conductor cable and representative housing covers to be applied therearound. Figure 15 is a view similar to that of Figure 14 showing the assembled housing covers on the cable. Figure 16 is a dual-conductor bus bar having two terminal assemblies of one embodiment of the present invention terminated to one of the conductors of the cable and two assemblies of an other embodiment of the present invention terminated to the other conductor of the invention. Figure 17 is a side view of a further embodiment of the present invention illustrating a tap connector interconnecting corresponding conductors of two dual-conductor cables. Figure 18 is a plan view of the embodiment of Figure 17 terminated to the cable. Figures 1 through 4 are representative of a prior art terminal assembly 20 used for interconnecting a single conductor cable to another electrical article, this assembly is disclosed in U.S. Patent 5,219,303. Terminal assembly 20 has a cable proximate surface 22 and a cable remote surface 24 and includes an upper plate portion 26 jointed at a hinge 46 to a lower plate section. The hinged portion includes aperture 48. The upper and lower plate sections 26,50 are adapted to be rotated and pressed together to establish electrical connections between conductors inserted therebetween. The upper plate portion 26 has a first portion 28 having a terminating region 30 and a second portion 36 having a terminating region 38. The first and second portions of upper plate 26 are separated by a transverse aperture 34. Upper plate section 26 further includes side walls 42 extending away from the cable proximate surface. Sidewalls 42 include ligature portions 44 at respective ends of aperture 34. Lower plate section 50 includes a first portion 52 having a terminating region 54 and a second portion 60 having a terminating region 62. The first and second portions of lower plate 50 are separated by a transverse aperture 58. Lower plate portion 50 further includes side wall 66 extending away from the cable proximate surface 22. Sidewalls 66 including ligature portions 68 at respective ends of aperture 58. Assembly 20 further includes a contact section 70 for electrical connection to an electrical article such as a terminal post or other means as known in the art. The upper and lower plate sections are joined by the hinged portion 46 and upon bending the terminal 20 at hinge 46 as shown in Figures 2 and 3, the corresponding first portions 28,52 and the corresponding second portions 36,60 are brought into opposing relationship. Terminal assembly 20 is designed to be terminated to a single conductor cable as shown in Figure 3 to a dual-conductor cable 72 having first and second isolated conductors 74,76 surrounded by insulation 78 and having an insulated section 80 therebetween. Upon inserting cable 72 between the opposed first and second plate portions and terminating the assembly as taught in U.S. Patent 5,219,303 the terminal assembly 20 is terminated to the corresponding conductors. Figure 3 shows the terminal assembly 20 prior to termination to cable 72 such that the two conductors 74,76 will be commoned. First and second sections 28,52; 36,60 of the upper and lower plate portions 26,50 include terminating regions 30,54; 38,62 comprising arrays of wave shapes alternating with arcuate relief shapes surrounding a cable receiving region. The wave shapes of each of the upper and lower plate portions 26,50 oppose the relief shapes of the other plate portions 50,26 to be received into the relief recesses they define during termination to the cable. Such wave shape termination is disclosed in U.S. Patent Nos. 4,867,700; 4,859,204 to shear conductor strips to expose conductor edges for gas-tight electrical connection interfaces with the terminals assembly. In terminating such portions insert members 31,39 have wave and relief shapes adapted to be disposed between the wave and relief shapes of the cable remote surface during termination. These inserts are affixed to the assembly preferably by light staking as disclosed in U.S. Patent No. 4,867,700. Application of terminal assembly 20 to the cables is preformed preferably with tooling including a ram to generate compression of the upper and lower terminal portions against the cables therebetween up to for example about 3,700 pounds (1 pound = 0.454 kg) for termination to a single cable 0.010 inches thick (1 inch = 25.4 mm) to 6,000 pounds for a pair of cables each 0.020 inches thick with heavy insulation. Figure 4 shows two terminal assemblies 20 terminated to a cable 72. A single assembly can be applied to the cable or cables and then severed at the respective ligatures to form a discrete terminals terminated to the two conductors of a dual-conductor cable. Thus when the assembly 20 further includes a contact section 70, only the hinge remote conductor is electrically connected thereto. This Figure also illustrates the severing at 45 of the respective ligatures 44 and ligatures 68 (not shown) by tooling such that the contact section 70 is electrically connected to conductor 74 that is the one that is remote to the hinge, as shown in the upper portion of Figure 4. The terminal assembly 20 in the lower portion is electrically terminated to its hinge remote conductor 76. As can be seen from Figure 4, the prior art assembly results in contact sections 70 extending from opposite edges of the dual-conductor cable 72 related to which conductor the assembly is terminated. The present invention, on the other hand, provides a terminal assembly that can be electrically connected to a selected conductor of a dual-conductor cable. Furthermore when the assembly includes a contact section extending from a hinge remote edge, all of the contact sections extend along the same edge of a multi-conductor cable regardless of the location of the selected conductor in the cable. Figures 5 through 8 show a first embodiment 84 of the present invention wherein the assembly 84 is adapted for termination to the hinge remote conductor of a dual-conductor cable. For purposes of illustration, the same numbers will be used for similar parts of the terminal assembly 84 and prior art assembly 20. Terminal assembly 84 has cable proximate surface 22 and a cable remote surface 24 and includes first or upper and second or lower plate sections 26 and 50 respectively joined at hinged portion 46. As seen in Figures 5 through 8 upper plate section 26 includes first portion 26 and second portion 36. Lower portion 50 includes first section 52 and second section 60. In this embodiment the terminating sections 38,62 of the second portion 36 of upper plate 26 and the second portion 60 of lower plate 50 have been severed from the formed blank prior to bending the assembly 84. Upon bending the assembly at hinged portion 46 the respective first portions 28,52 are brought into alignment in an opposed relationship such that upon inserting the dual-conductor cable 72 therebetween the terminating sections 54 and 30 are brought into alignment to be terminated to the first conductor or hinge remote conductor 74. Upon terminating the assembly 84 with the insert 31, as shown in Figure 8, contact 70 is electrically connected to conductor 74 and only conductor 74. Referring now to Figures 9 through 13, a second embodiment 94 of the present invention is adapted for terminating to the hinge proximate conductor 76 of a dual-conductor cable 72. Figure 9 shows an alternative method for making the terminal assembly of the present invention in which a flat member is stamped from a strip of material and the flat blank is then formed such that the corresponding terminating regions of the assembly are removed prior to forming the side walls 44,66 and the shearing portions 40,64 of the selected terminating sections 36,60. In the embodiment shown in Figures 9 through 13 the second portions 36,62 of the upper and lower plate sections 26,50 are formed into the shearing means 40,64. Upon bending the first and second plate portions 26,50 at hinged portion 46 the respective second portions 36,60 lie in opposed relationship such that upon inserting a cable therebetween and pressing the two plate sections together, the hinge proximate conductor 76 is terminated to the assembly 94 thus interconnecting contact member 70 to the hinge proximate conductor 76. Figures 14 and 15 illustrate the embodiment 102 wherein the terminal assembly 84 is enclosed within housing covers 98 to form an insulated connection. Figure 14 further shows more clearly the insert 31 used in terminating the assembly to the cable remote conductor 74. Figure 16 shows a bus bar assembly 104 for having two of the terminal assemblies 84 terminated to the remote conductor 74 and two of the terminal assemblies 94 terminated to the cable proximate conductor 76. As can be seen in Figure 16 all of the contact portions 70 extend along the same edge of bus bar assembly 104. Conductors 74,76 in bus bar assembly 104 can be of the same or different voltages enabling interconnection to devices such as circuit boards or the like requiring different voltages, as well as the positive and ground of a power supply, for example. The present invention offers a distinct advantage over the conductor of the prior art in that there is no need to provide or use further tooling to sever the ligatures to isolate one or the other conductors and furthermore there is no need to rotate the assembly 180° to attach the assembly to a different conductor. Figures 17 and 18 show a further embodiment 106 of the present invention wherein the terminal assembly is used as a tap connector to electrically interconnect corresponding conductors of two or more cables. As shown in these Figures, the first section termination regions 30, and 54 remain in the assembly, while the second terminating regions 38, 54 have been removed. Upon applying pressure and terminating the assembly 106 to the cable the hinge remote conductor 74 of the two cables are electrically interconnected while keeping the hinge proximate conductors 76 electrically isolated from one another. It is thought that the terminal assembly of the present invention and many of its attendant advantages will be understood from the foregoing description. It is apparent that various changes may be made in the form, construction, and arrangement of the parts thereof without sacrificing all of its material advantages.

Claims: A terminal (84,94) for terminating an intermediate portion of a selected conductor of a flat cable (72) having at least two conductors (74,76) separated by an insulating section (80), the terminal comprising upper and lower plate sections (26,50) connected by a hinge portion (46) and being foldable along the hinge portion (46) to form a cable receiving recess between the upper and lower plate sections (26,50), each of the plate sections having first sections (28,52) remote from the hinge portion (46) for being brought into alignment with a first one of the conductors (74), and each of the plate sections (26,50) having second sections (36,60) near the hinge portion (46) for being brought into alignment with a second one of the conductors (76), characterized in that the terminal has terminating sections (30,54,38,62) on the upper and lower plate sections (26,50) only in the first sections (28,52) for electrically terminating to the first conductor (74) or in the second sections (36,60) for electrically terminating to the second conductor (76). The terminal of claim 1, wherein the terminating sections (30,54,38,62) include shearing sections for shearing insulation (78) around the conductor (74,76) being terminated. The terminal of claim 1 or 2, wherein a contact section (70) extends from an end of one of the upper and lower plate sections (26,50) remote from the hinge portion (46). The terminal of claim 1, 2 or 3, wherein said terminating sections (30,54,38,62) include arrays of wave shapes alternating with arcuate relief shapes, the wave shapes of each of the upper and lower plate sections (26,50) oppose the relief shapes of the other plate section. The terminal of any preceding claim, wherein said terminal is secured in a housing (102) after terminating to the cable (72). The terminal of any preceding claim, wherein said terminal receives two flat cables (72) between the upper and lower plate sections (26,50) for termination to one of the corresponding conductors (74,76) in each cable. The terminal of any preceding claim, wherein the terminating sections (30,54) are in the first sections (28,52) of the upper and lower plate sections (26,50) for electrically terminating to the first conductor (74). The terminal of claim 7, wherein the second sections (36,60) of the upper and lower plate sections (26,50) define an opening therebetween for accommodating the second conductor (76). The terminal of any one of claims 1 to 6, wherein the terminating sections (38,62) are in the second sections (36,60) of the upper and lower plate sections (26,50) for electrically terminating to the second conductor (76). The terminal of claim 9, wherein the first sections (28,52) of the upper and lower plate sections (26,50) define an opening therebetween for accommodating the first conductor (74).

Inventors: BABOW DAVID ALAN, POLK ROGER NORMAN, BABOW, DAVID ALAN, POLK, ROGER NORMAN
Applicants: WHITAKER CORP, THE WHITAKER CORPORATION
Application year: 1994
Main classification: H01R9
IPC codes: H01R12, H01R4